JP6939584B2

JP6939584B2 - Manufacturing method of cable with resin molded body

Info

Publication number: JP6939584B2
Application number: JP2018002714A
Authority: JP
Inventors: 池田　幸雄; 幸雄池田
Original assignee: Hitachi Metals Ltd
Current assignee: Hitachi Metals Ltd
Priority date: 2018-01-11
Filing date: 2018-01-11
Publication date: 2021-09-22
Anticipated expiration: 2038-01-11
Also published as: JP2019121577A

Description

本発明は、端部に樹脂成形体が設けられたケーブルに関するものである。 The present invention relates to a cable provided with a resin molded body at an end.

今日、電力用ケーブルや通信用ケーブル等の各種ケーブルが様々な分野で使用されている。このようなケーブルの一つに、心線と、当該心線の周囲に設けられたシースと、シースの端部から突出している心線の先端に接続された電子部品と、これらシース端部，心線の露出部分および心線に接続された電子部品が収容されたホルダと、当該ホルダの全周（全体）を被覆する樹脂製のアウターと、を有する樹脂成形体付きケーブルがある。この種のケーブルは、例えば、ＡＢＳセンサ，トルクセンサ，インデックスセンサ等の車載センサに用いられる。以下の説明では、シース端部，心線の露出部分および電子部品を「ケーブル端部」と総称する場合がある。つまり、ホルダに収容されている要素を「ケーブル端部」と総称する場合がある。 Today, various cables such as electric power cables and communication cables are used in various fields. One such cable includes a core wire, a sheath provided around the core wire, an electronic component connected to the tip of the core wire protruding from the end of the sheath, and the end of the sheath. There is a cable with a resin molded body having a holder containing an exposed portion of the core wire and electronic components connected to the core wire, and a resin outer covering the entire circumference (whole) of the holder. This type of cable is used, for example, in an in-vehicle sensor such as an ABS sensor, a torque sensor, and an index sensor. In the following description, the sheath end, the exposed part of the core wire, and the electronic component may be collectively referred to as the "cable end". That is, the elements housed in the holder may be collectively referred to as "cable end".

上記のような樹脂成形体付きケーブルは、ケーブル端部を樹脂製のホルダに収容し、ケーブル端部が収容されたホルダを金型内にセットし、ホルダがセットされた金型内に樹脂材料を供給してアウターを成形することによって製造される。また、ホルダは、互いに突き合わされた下側ホルダ部材および上側ホルダ部材から形成されている。ケーブル端部をホルダに収容する際には、下側ホルダ部材の上にケーブル端部を載置し、ケーブル端部が載置された下側ホルダ部材に上側ホルダ部材を重ね合わせる。つまり、ケーブル端部をホルダに収容するためには、下側ホルダ部材と上側ホルダ部材との間にケーブル端部を挟み込む必要がある。 For a cable with a resin molded body as described above, the end of the cable is housed in a resin holder, the holder containing the end of the cable is set in a mold, and the resin material is placed in the mold in which the holder is set. Is manufactured by supplying and molding the outer. Further, the holder is formed of a lower holder member and an upper holder member that are abutted against each other. When accommodating the cable end in the holder, the cable end is placed on the lower holder member, and the upper holder member is superposed on the lower holder member on which the cable end is placed. That is, in order to accommodate the cable end in the holder, it is necessary to sandwich the cable end between the lower holder member and the upper holder member.

特開２０１６−４６８８号公報Japanese Unexamined Patent Publication No. 2016-4688

上記樹脂成形体付きケーブルを製造するためには、アウターを成形する前に、ケーブル端部を下側ホルダ部材と上側ホルダ部材との間に挟み込んでホルダ内に収容する必要があり、製造工程数が多かった。また、ホルダが２つの半割れ部材から形成されているので部品点数が多かった。さらに、ホルダの全周（全体）を覆うアウターを成形するために多くの樹脂材料が必要であった。総じて、従来の樹脂成形体付きケーブルは製造コストが高かった。 In order to manufacture the cable with the resin molded body, it is necessary to sandwich the end of the cable between the lower holder member and the upper holder member and accommodate the cable in the holder before molding the outer, and the number of manufacturing steps is large. There were many. Further, since the holder is formed of two half-split members, the number of parts is large. In addition, a large amount of resin material was required to form the outer covering the entire circumference (whole) of the holder. As a whole, the conventional cable with a resin molded body has a high manufacturing cost.

本発明の目的は、樹脂成形体付きケーブルの製造コストを低減することである。 An object of the present invention is to reduce the manufacturing cost of a cable with a resin molded body.

本発明の樹脂成形体付きケーブルは、絶縁電線および前記絶縁電線の周囲に設けられたシースを備えるケーブルと、前記ケーブルの端部に接続された電子部品と、前記ケーブルの前記端部および前記電子部品を被覆する樹脂成形体と、を有する。前記樹脂成形体は、前記シースの端部，前記シースの前記端部から突出している前記絶縁電線の被覆部分，前記被覆部分から突出している前記絶縁電線の導体部分および前記導体部分が接続された前記電子部品が載置される搭載部と、当該搭載部を取り囲む枠部と、を備えるホルダ部材と、前記搭載部に載置された前記シースの前記端部，前記絶縁電線の前記被覆部分，前記絶縁電線の前記導体部分および前記電子部品を前記ホルダ部材の一部と共に被覆するカバー部材と、から形成される。そして、少なくとも前記ホルダ部材の前記枠部の表面は、前記カバー部材が成形される際の熱によって当該カバー部材に溶着されており、前記枠部の前記表面には、前記カバー部材に食い込む突起片が形成されている。 The cable with a resin molded body of the present invention includes a cable having an insulated wire and a sheath provided around the insulated wire, an electronic component connected to the end of the cable, the end of the cable, and the electron. It has a resin molded body that covers the parts. In the resin molded body, an end portion of the sheath, a coated portion of the insulated wire protruding from the end portion of the sheath, a conductor portion of the insulated wire protruding from the coated portion, and the conductor portion were connected. A holder member including a mounting portion on which the electronic component is mounted, a frame portion surrounding the mounting portion, the end portion of the sheath mounted on the mounting portion, the covering portion of the insulated wire, and the like. It is formed of a conductor portion of the insulated wire and a cover member that covers the electronic component together with a part of the holder member. Then, at least the surface of the frame portion of the holder member is welded to the cover member by the heat when the cover member is formed, and the surface of the frame portion is a protrusion piece that bites into the cover member. Is formed.

本発明によれば、樹脂成形体付きケーブルの低コスト化が実現される。 According to the present invention, the cost of the cable with a resin molded body can be reduced.

ケーブルの構造を示す図である。It is a figure which shows the structure of a cable. 樹脂成形体の外観を示す図である。It is a figure which shows the appearance of the resin molded body. ホルダ部材の構造を示す図である。It is a figure which shows the structure of a holder member. ホルダ部材の構造を示す他の図である。It is another figure which shows the structure of a holder member. 樹脂成形体の内部を示す図である。It is a figure which shows the inside of the resin molded body. 突起片を示す図である。It is a figure which shows the protrusion piece. 突起片の変形例の一つを示す図である。It is a figure which shows one of the deformation examples of a protrusion piece. 突起片の変形例の他の一つを示す図である。It is a figure which shows another one of the deformation example of a protrusion piece.

次に、本発明の樹脂成形体付きケーブルの実施形態の一例について図面を参照しながら詳細に説明する。本実施形態に係る樹脂成形体付きケーブルは、ケーブルと、ケーブル端部に接続された電子部品（本実施形態ではセンサ）と、ケーブル端部および電子部品を被覆する樹脂成形体と、を有する。 Next, an example of the embodiment of the cable with the resin molded body of the present invention will be described in detail with reference to the drawings. The cable with a resin molded body according to the present embodiment includes a cable, an electronic component (sensor in this embodiment) connected to the cable end, and a resin molded body that covers the cable end and the electronic component.

図１に示されるように、ケーブル１は、一対の絶縁電線３，４と、これら絶縁電線３，４を一括して被覆するシース５と、を有する。言い換えれば、ケーブル１は、一対の絶縁電線３，４を心線とする２心ケーブルである。 As shown in FIG. 1, the cable 1 has a pair of insulated wires 3 and 4 and a sheath 5 that collectively covers the insulated wires 3 and 4. In other words, the cable 1 is a two-core cable having a pair of insulated wires 3 and 4 as core wires.

それぞれの絶縁電線３，４は、導体６と、導体６の周囲に設けられた絶縁層７と、を有する。導体６は複数本の素線が集合撚りされた撚り線であり、絶縁層７はウレタンによって形成されている。導体６を形成する素線の種類は特に限定されないが、例えば、軟銅線，硬銅線，すずめっき軟銅線，すずめっき硬銅線などを用いることができる。素線の撚り方法も集合撚りに限定されるものではなく、例えば、同心撚りや複合撚りであってもよい。また、絶縁層７はウレタン以外の樹脂材料によって形成してもよい。 Each of the insulated wires 3 and 4 has a conductor 6 and an insulating layer 7 provided around the conductor 6. The conductor 6 is a stranded wire in which a plurality of strands are collectively twisted, and the insulating layer 7 is formed of urethane. The type of wire forming the conductor 6 is not particularly limited, and for example, annealed copper wire, a hard copper wire, a tin-plated annealed copper wire, a tin-plated hard copper wire, or the like can be used. The method of twisting the strands is not limited to collective twisting, and may be, for example, concentric twisting or composite twisting. Further, the insulating layer 7 may be formed of a resin material other than urethane.

シース５はウレタンによって形成されており、互いに平行に配置された絶縁電線３，４を一括して被覆している。このシース５によって一対の絶縁電線３，４の間隔が保持されている。もっとも、ウレタン以外の樹脂材料によってシース５を形成してもよい。 The sheath 5 is made of urethane and collectively covers the insulated wires 3 and 4 arranged in parallel with each other. The sheath 5 maintains the distance between the pair of insulated wires 3 and 4. However, the sheath 5 may be formed of a resin material other than urethane.

図１に示されるように、ケーブル１の少なくとも一方の端末において絶縁電線３，４が露出している。具体的には、シース５の少なくとも一方の端部５ａから絶縁電線３，４がそれぞれ突出している。より具体的には、シース５の少なくとも一方の端面５ｂから絶縁電線３，４がそれぞれ突出している。 As shown in FIG. 1, the insulated wires 3 and 4 are exposed at at least one end of the cable 1. Specifically, the insulated wires 3 and 4 project from at least one end 5a of the sheath 5. More specifically, the insulated wires 3 and 4 project from at least one end surface 5b of the sheath 5.

図２に示されるように、樹脂成形体８は、所定の樹脂材料によって成形されたホルダ部材１０およびカバー部材３０から形成されており、カバー部材３０はホルダ部材１０を部分的に被覆している。 As shown in FIG. 2, the resin molded body 8 is formed of a holder member 10 and a cover member 30 formed of a predetermined resin material, and the cover member 30 partially covers the holder member 10. ..

図３，図４に示されるように、ホルダ部材１０は全体として半円柱状の外観を呈し、このホルダ部材１０が有する搭載部１１にケーブル１の端部およびセンサ４０が載置されている。ホルダ部材１０の搭載部１１には、シース端部５ａが収容されるシース収容部１２と、絶縁電線３，４の根元部分３ａ，４ａが置かれる被覆部載置面１３と、それぞれの絶縁電線３，４の導体６が置かれる導体載置面１４ａ，１４ｂと、センサ４０が収容される電子部品収容部１５と、が含まれる。シース収容部１２、被覆部載置面１３、導体載置面１４ａ，１４ｂおよび電子部品収容部１５は、ホルダ部材１０の長手方向に沿ってこの順で配置されている。また、搭載部１１の周囲には、当該搭載部１１を取り囲む枠部１６が設けられている。言い換えれば、枠部１６の内側に、シース収容部１２等から構成される搭載部１１が設けられている。 As shown in FIGS. 3 and 4, the holder member 10 has a semi-cylindrical appearance as a whole, and the end portion of the cable 1 and the sensor 40 are mounted on the mounting portion 11 included in the holder member 10. The mounting portion 11 of the holder member 10 includes a sheath accommodating portion 12 in which the sheath end portion 5a is accommodated, a covering portion mounting surface 13 in which the root portions 3a and 4a of the insulated wires 3 and 4 are placed, and each insulated electric wire. Includes conductor mounting surfaces 14a and 14b on which the conductors 6 of 3 and 4 are placed, and an electronic component accommodating portion 15 in which the sensor 40 is housed. The sheath accommodating portion 12, the covering portion mounting surface 13, the conductor mounting surfaces 14a and 14b, and the electronic component accommodating portion 15 are arranged in this order along the longitudinal direction of the holder member 10. Further, a frame portion 16 surrounding the mounting portion 11 is provided around the mounting portion 11. In other words, a mounting portion 11 composed of a sheath accommodating portion 12 and the like is provided inside the frame portion 16.

搭載部１１の構成要素の一つであるシース収容部１２は、シース端部５ａの径方向略半分（下半分）を収容可能な半円状の断面形状を有する。一方、導体載置面１４ａ，１４ｂは、ホルダ部材１０の長手方向に沿って互いに平行に延びる細長の平坦面である。これら２つの導体載置面１４ａ，１４ｂの間には、それぞれの導体載置面１４ａ，１４ｂに置かれた導体６同士の接触を防止する凸部１７が設けられている。凸部１７は、導体載置面１４ａ，１４ｂと同一または略同一の長さを有し、導体載置面１４ａ，１４ｂと平行に延びている。 The sheath accommodating portion 12, which is one of the components of the mounting portion 11, has a semicircular cross-sectional shape capable of accommodating substantially half (lower half) of the sheath end portion 5a in the radial direction. On the other hand, the conductor mounting surfaces 14a and 14b are elongated flat surfaces extending parallel to each other along the longitudinal direction of the holder member 10. Between these two conductor mounting surfaces 14a and 14b, a convex portion 17 is provided to prevent contact between the conductors 6 placed on the respective conductor mounting surfaces 14a and 14b. The convex portion 17 has the same or substantially the same length as the conductor mounting surfaces 14a and 14b, and extends in parallel with the conductor mounting surfaces 14a and 14b.

被覆部載置面１３は、シース収容部１２と導体載置面１４ａ，１４ｂとの間に設けられた平坦面であって、この被覆部載置面１３の上に、シース端部５ａから突出している絶縁電線３，４の根元部分３ａ，４ａが置かれている。具体的には、シース端部５ａから突出している絶縁電線３，４の露出部分のうち、絶縁層７（図１）によって被覆されている部分の全部または一部が被覆部載置面１３の上に置かれている。つまり、絶縁電線３，４の露出部分のうち、絶縁層７（図１）に覆われている被覆部分が被覆部載置面１３の上に置かれている。また、絶縁電線３，４の露出部分のうち、絶縁層７（図１）に覆われていない導体部分が導体載置面１４ａ，１４ｂの上に置かれている。そして、それぞれの絶縁電線３，４の導体６の先端が、導体載置面１４ａ，１４ｂの前方に設けられている電子部品収容部１５に収容されているセンサ４０に接続されている。本実施形態におけるセンサ４０は、周囲の磁界変化に応じた信号を出力する磁気センサである。 The covering portion mounting surface 13 is a flat surface provided between the sheath accommodating portion 12 and the conductor mounting surfaces 14a and 14b, and protrudes from the sheath end portion 5a on the covering portion mounting surface 13. The root portions 3a and 4a of the insulated wires 3 and 4 are placed. Specifically, of the exposed portions of the insulated wires 3 and 4 protruding from the sheath end portion 5a, all or part of the portion covered by the insulating layer 7 (FIG. 1) is the covering portion mounting surface 13. It is placed on top. That is, among the exposed portions of the insulated wires 3 and 4, the covered portion covered with the insulating layer 7 (FIG. 1) is placed on the covering portion mounting surface 13. Further, among the exposed portions of the insulated wires 3 and 4, the conductor portion not covered by the insulating layer 7 (FIG. 1) is placed on the conductor mounting surfaces 14a and 14b. Then, the tip of the conductor 6 of each of the insulated wires 3 and 4 is connected to the sensor 40 housed in the electronic component accommodating portion 15 provided in front of the conductor mounting surfaces 14a and 14b. The sensor 40 in this embodiment is a magnetic sensor that outputs a signal according to a change in an ambient magnetic field.

ホルダ部材１０の長手方向略中央には、同方向に対して直交する方向に延びる突出部１８が一体成形されている。また、ホルダ部材１０の枠部１６の表面１６ａには、当該枠部１６の全長に亘って薄板状の突起片２０が形成されている。さらに、ホルダ部材１０の後端面１９にも、当該後端面１９に沿って延びる薄板状の突起片２０が形成されている。もっとも、枠部表面１６ａに形成されている突起片２０と後端面１９に形成されている突起片２０は、切れ目なく繋がっている一連の突起片２０である。そこで、以下の説明では、枠部表面１６ａに形成されている突起片２０と後端面１９に形成されている突起片２０とを特に区別することなく「突起片２０」と総称する。 A protrusion 18 extending in a direction orthogonal to the same direction is integrally formed at substantially the center of the holder member 10 in the longitudinal direction. Further, a thin plate-shaped protrusion 20 is formed on the surface 16a of the frame portion 16 of the holder member 10 over the entire length of the frame portion 16. Further, the rear end surface 19 of the holder member 10 is also formed with a thin plate-shaped protrusion 20 extending along the rear end surface 19. However, the protrusion 20 formed on the frame surface 16a and the protrusion 20 formed on the rear end surface 19 are a series of protrusions 20 that are seamlessly connected. Therefore, in the following description, the protrusions 20 formed on the frame surface 16a and the protrusions 20 formed on the rear end surface 19 are collectively referred to as "protrusions 20" without any particular distinction.

突起片２０は、枠部表面１６ａおよび後端面１９の幅方向略中央に形成されており、枠部表面１６ａまたは後端面１９から略垂直に立ち上がっている。また、突起片２０は、枠部表面１６ａまたは後端面１９から離反するに連れて次第に先細りになる断面形状（本実施形態では三角形または略三角形の断面形状）を有する。 The protrusion 20 is formed substantially in the center of the frame portion surface 16a and the rear end surface 19 in the width direction, and rises substantially vertically from the frame portion surface 16a or the rear end surface 19. Further, the protruding piece 20 has a cross-sectional shape (in this embodiment, a triangular or substantially triangular cross-sectional shape) that gradually tapers as it separates from the frame portion surface 16a or the rear end surface 19.

図２，図５に示されるように、カバー部材３０は、ホルダ部材１０に載置されているケーブル１の端部およびセンサ４０をホルダ部材１０の一部と共に被覆している。具体的には、カバー部材３０は、シース端部５ａ，絶縁電線３，４の露出部分（被覆部分および導体部分）およびセンサ４０を被覆している。また、カバー部材３０は、これらシース端部５ａ等が載置されている搭載部１１（図３）を取り囲んでいるホルダ部材１０の枠部表面１６ａおよび後端面１９も被覆している。言い換えれば、ホルダ部材１０の外周面は、実質的にカバー部材３０によって被覆されておらず、露出している。 As shown in FIGS. 2 and 5, the cover member 30 covers the end of the cable 1 mounted on the holder member 10 and the sensor 40 together with a part of the holder member 10. Specifically, the cover member 30 covers the sheath end portion 5a, the exposed portions (covered portion and conductor portion) of the insulated wires 3 and 4, and the sensor 40. Further, the cover member 30 also covers the frame portion surface 16a and the rear end surface 19 of the holder member 10 surrounding the mounting portion 11 (FIG. 3) on which the sheath end portion 5a and the like are mounted. In other words, the outer peripheral surface of the holder member 10 is substantially not covered by the cover member 30 and is exposed.

もっとも、ホルダ部材１０の突出部１８は、その全周（全体）がカバー部材３０によって被覆されている。そして、ホルダ部材１０の突出部１８を被覆しているカバー部材３０の一部により、貫通孔５０を備えるフランジ部５１が形成されている。つまり、ホルダ部材１０の突出部１８は、フランジ部５１の芯材としての役割を有する。樹脂成形体８（センサ４０）を所望の取付け位置に固定する際には、フランジ部５１が備える貫通孔５０に挿通させたボルトを取付け位置に予め設けられているボルト穴にねじ結合させる。 However, the entire circumference (whole) of the protruding portion 18 of the holder member 10 is covered with the cover member 30. A flange portion 51 having a through hole 50 is formed by a part of the cover member 30 that covers the protruding portion 18 of the holder member 10. That is, the protruding portion 18 of the holder member 10 has a role as a core material of the flange portion 51. When fixing the resin molded body 8 (sensor 40) to a desired mounting position, a bolt inserted through a through hole 50 provided in the flange portion 51 is screw-coupled to a bolt hole provided in advance at the mounting position.

カバー部材３０は、ケーブル１の端部およびセンサ４０が載置されたホルダ部材１０（図４）を金型内にセットし、ホルダ部材１０がセットされた金型内に加熱溶融させた樹脂材料を供給することによって成形されたものである。ここで、ホルダ部材１０がセットされた金型内に加熱溶融させた樹脂材料を供給すると、供給された樹脂材料と接したホルダ部材１０およびシース端部５ａの表層部が溶解する。この結果、少なくともホルダ部材１０の枠部表面１６ａ，後端面１９およびシース端部５ａの表面がカバー部材３０と溶着し、気密性や防水性が確保される。つまり、ホルダ部材１０の枠部表面１６ａ，後端面１９およびシース端部５ａの表面は、カバー部材３０が成形される際の熱により当該カバー部材３０と溶着している。 The cover member 30 is a resin material in which the end of the cable 1 and the holder member 10 (FIG. 4) on which the sensor 40 is placed are set in a mold and heated and melted in the mold in which the holder member 10 is set. It is formed by supplying. Here, when the heat-melted resin material is supplied into the mold in which the holder member 10 is set, the holder member 10 in contact with the supplied resin material and the surface layer portion of the sheath end portion 5a are melted. As a result, at least the surface of the frame portion surface 16a, the rear end surface 19 and the sheath end portion 5a of the holder member 10 are welded to the cover member 30, and airtightness and waterproofness are ensured. That is, the surface of the frame portion surface 16a, the rear end surface 19 and the sheath end portion 5a of the holder member 10 are welded to the cover member 30 by the heat generated when the cover member 30 is formed.

さらに、図６に示されるように、上記のようにして成形されたカバー部材３０には、ホルダ部材１０の枠部表面１６ａおよび後端面１９に予め形成されていた突起片２０が食い込むとともに、当該突起片２０の表面もカバー部材３０と溶着する。このように、ホルダ部材１０の搭載部１１（図４）を取り囲んでいる一連の突起片２０がカバー部材３０に食い込むことにより、気密性や防水性がさらに向上する。尚、突起片２０の高さ（Ｈ）は０．５〜１．０ｍｍ程度が好ましく、突起片２０の中心角（θ）は１５〜６０°が好ましい。 Further, as shown in FIG. 6, the cover member 30 formed as described above is covered with the protrusions 20 previously formed on the frame portion surface 16a and the rear end surface 19 of the holder member 10. The surface of the protrusion 20 is also welded to the cover member 30. In this way, the series of protrusions 20 surrounding the mounting portion 11 (FIG. 4) of the holder member 10 bites into the cover member 30, thereby further improving the airtightness and waterproofness. The height (H) of the protrusion 20 is preferably about 0.5 to 1.0 mm, and the central angle (θ) of the protrusion 20 is preferably 15 to 60 °.

カバー部材３０が成形される際の熱によって当該カバー部材３０とホルダ部材１０との界面を溶着させる観点からは、ホルダ部材１０を形成する樹脂材料よりも融点が高い樹脂材料によってカバー部材３０を形成することが好ましい。例えば、ホルダ部材１０をポリアミド（ＰＡ）によって形成し、カバー部材３０をポリフタルアミド（ＰＰＡ）によって形成することが好ましい。尚、ポリフタルアミド（ＰＰＡ）の融点は約３２０℃である。 From the viewpoint of welding the interface between the cover member 30 and the holder member 10 by the heat generated when the cover member 30 is formed, the cover member 30 is formed of a resin material having a melting point higher than that of the resin material forming the holder member 10. It is preferable to do so. For example, it is preferable that the holder member 10 is formed of polyamide (PA) and the cover member 30 is formed of polyphthalamide (PPA). The melting point of polyphthalamide (PPA) is about 320 ° C.

本実施形態に係る樹脂成形体付きケーブルが有する樹脂成形体８は、ホルダ部材１０と、このホルダ部材１０を部分的に被覆するカバー部材３０と、から形成されている。よって、２つの半割れ部材から形成されるホルダと、このホルダの全周（全体）を被覆するアウターと、から形成される樹脂成形体を有する従来の樹脂成形体付きケーブルに比べて部品点数が少ない。また、本実施形態における樹脂成形体８は、ケーブル端部等が載置されたホルダ部材１０の上にカバー部材３０を直接成形することによって形成される。よって、本実施形態に係る樹脂成形体付きケーブルは、アウター成形に先立ってケーブル端部等をホルダ内に収容する必要がある従来の樹脂成形体付きケーブルよりも少ない工程数で製造することができる。さらに、本実施形態における樹脂成形体８を形成するカバー部材３０は、ホルダ部材１０の一部のみを覆っている。つまり、カバー部材３０は、ホルダの全周（全体）を被覆する従来のアウターを成形するために必要な樹脂材料よりも少ない量の樹脂材料によって成形することができる。このように、本実施形態に係る樹脂成形体付きケーブルは、従来の樹脂成形体付きケーブルと比べて、少ない部品，少ない材料，少ない工程で製造することができる。 The resin molded body 8 included in the cable with a resin molded body according to the present embodiment is formed of a holder member 10 and a cover member 30 that partially covers the holder member 10. Therefore, the number of parts is larger than that of a conventional cable with a resin molded body having a resin molded body formed of a holder formed of two half-split members and an outer covering the entire circumference (whole) of the holder. few. Further, the resin molded body 8 in the present embodiment is formed by directly molding the cover member 30 on the holder member 10 on which the cable end and the like are placed. Therefore, the cable with a resin molded body according to the present embodiment can be manufactured with a smaller number of steps than the conventional cable with a resin molded body, which needs to accommodate the cable end and the like in the holder prior to outer molding. .. Further, the cover member 30 forming the resin molded body 8 in the present embodiment covers only a part of the holder member 10. That is, the cover member 30 can be molded with a resin material in an amount smaller than the resin material required for molding the conventional outer covering the entire circumference (entire) of the holder. As described above, the cable with a resin molded body according to the present embodiment can be manufactured with fewer parts, fewer materials, and fewer steps than the conventional cable with a resin molded body.

加えて、本実施形態における樹脂成形体８を形成するホルダ部材１０には、ケーブル端部等が載置される搭載部１１を取り囲むとともに、カバー部材３０に食い込む一連の突起片２０が設けられている。よって、ケーブル端部等に対する気密性や防水性が高い。 In addition, the holder member 10 forming the resin molded body 8 in the present embodiment is provided with a series of protrusions 20 that surround the mounting portion 11 on which the cable end and the like are placed and that bite into the cover member 30. There is. Therefore, the airtightness and waterproofness to the cable end and the like are high.

本発明は上記実施形態に限定されるものでなく、その趣旨を変更しない範囲で種々の変更が可能である。例えば、図３等に示される突起片２０を枠部１６の一部に形成してもよい。また、図３等に示される突起片２０の外側または内側に、当該突起片２０に沿う一連の第２突起片を形成してもよい。具体的には、図７に示されるように、突起片２０の外側に、当該突起片２０を取り囲む第２突起片２１を形成してもよい。以下の説明では、突起片２０を「内側突起片２０」、第２突起片２１を「外側突起片２１」と呼ぶ。つまり、内側突起片２０の周囲に当該内側突起片２０を取り囲む外側突起片２１が形成された二重構造としてもよい。このような二重構造を採用すれば、内側突起片２０または外側突起片２１のいずれか一方に亀裂２２が発生したとしても、気密性や防水性が低下することがない。 The present invention is not limited to the above embodiment, and various modifications can be made without changing the gist thereof. For example, the protrusion 20 shown in FIG. 3 or the like may be formed in a part of the frame portion 16. Further, a series of second protrusions along the protrusion 20 may be formed on the outside or inside of the protrusion 20 shown in FIG. 3 or the like. Specifically, as shown in FIG. 7, a second protrusion 21 surrounding the protrusion 20 may be formed on the outside of the protrusion 20. In the following description, the protrusion 20 will be referred to as an "inner protrusion 20" and the second protrusion 21 will be referred to as an "outer protrusion 21". That is, it may be a double structure in which the outer protrusion piece 21 surrounding the inner protrusion piece 20 is formed around the inner protrusion piece 20. If such a double structure is adopted, even if a crack 22 occurs in either the inner protrusion piece 20 or the outer protrusion piece 21, the airtightness and waterproofness do not deteriorate.

さらに、図８に示されるように、内側突起片２０と外側突起片２１との間に、これら突起片２０，２１と交差する方向に延びる複数の架橋突起片２３を形成してもよい。これら複数の架橋突起片２３は、突起片２０，２１に沿って互いに平行に配置されている。また、それぞれの架橋突起片２３の一端は内側突起片２０に連接され、他端は外側突起片２１に連接されている。つまり、内側突起片２０と外側突起片２１との間の隙間が複数の架橋突起片２３によって区画されたセル構造としてもよい。このようなセル構造を採用すれば、内側突起片２０および外側突起片２１の双方に亀裂２２が発生したとしても、その亀裂２２の発生個所が同一のセルでない限り、気密性や防水性が低下することがない。 Further, as shown in FIG. 8, a plurality of crosslinked protrusions 23 extending in a direction intersecting the protrusions 20 and 21 may be formed between the inner protrusions 20 and the outer protrusions 21. These plurality of crosslinked protrusions 23 are arranged parallel to each other along the protrusions 20 and 21. Further, one end of each of the crosslinked projection pieces 23 is connected to the inner protrusion piece 20, and the other end is connected to the outer protrusion piece 21. That is, a cell structure may be formed in which the gap between the inner protrusion piece 20 and the outer protrusion piece 21 is partitioned by a plurality of crosslinked protrusion pieces 23. If such a cell structure is adopted, even if cracks 22 occur in both the inner protrusion piece 20 and the outer protrusion piece 21, the airtightness and waterproofness are lowered unless the cracks 22 are generated in the same cell. There is nothing to do.

ケーブル１は２心ケーブルに限定されるものではなく、単心ケーブルであっても、３心以上のケーブルであってもよい。ホルダ部材１０やカバー部材３０を形成する材料は、上記樹脂材料に限定されない。例えば、カバー部材３０を形成する樹脂材料として、ポリフェニレンスルファイド（ＰＰＳ(Polyphenylenesulfide)）を選択することができる。 The cable 1 is not limited to a two-core cable, and may be a single-core cable or a cable having three or more cores. The material forming the holder member 10 and the cover member 30 is not limited to the above resin material. For example, polyphenylene sulfide (PPS) can be selected as the resin material for forming the cover member 30.

また、ケーブル１のシース５や絶縁電線３，４の絶縁層７はウレタン以外の絶縁性樹脂、例えばポリブチレンテレフタレート（ＰＢＴ（Polybutylene terephthalate））によって形成することもできる。また、センサ４０は、樹脂成形体付きケーブルの用途に応じて他の電子部品に置換される。 Further, the sheath 5 of the cable 1 and the insulating layer 7 of the insulated wires 3 and 4 can be formed of an insulating resin other than urethane, for example, polybutylene terephthalate (PBT). Further, the sensor 40 is replaced with another electronic component depending on the use of the cable with a resin molded body.

１ケーブル
３，４絶縁電線
３ａ，４ａ根元部分
５シース
５ａシースの端部（シース端部）
５ｂ端面
６導体
７絶縁層
８樹脂成形体
１０ホルダ部材
１１搭載部
１２シース収容部
１３被覆部載置面
１４ａ，１４ｂ導体載置面
１５電子部品収容部
１６枠部
１６ａ表面（枠部表面）
１７凸部
１８突出部
１９後端面
２０突起片（内側突起片）
２１第２突起片（外側突起片）
２２亀裂
２３架橋突起片
３０カバー部材
４０センサ
５０貫通孔
５１フランジ部 1 Cable 3, 4 Insulated wire 3a, 4a Root part 5 Sheath 5a Sheath end (sheath end)
5b End face 6 Conductor 7 Insulation layer 8 Resin molded body 10 Holder member 11 Mounting part 12 Sheath housing part 13 Covering part mounting surface 14a, 14b Conductor mounting surface 15 Electronic component housing part 16 Frame part 16a Surface (frame part surface)
17 Convex part 18 Protruding part 19 Rear end surface 20 Protruding piece (inner protruding piece)
21 Second protrusion (outer protrusion)
22 Crack 23 Cross-linked protrusion 30 Cover member 40 Sensor 50 Through hole 51 Flange

Claims

A cable having an insulated wire and a sheath provided around the insulated wire,
Electronic components connected to the end of the cable
It has the end of the cable and a resin molded body that covers the electronic component.
The resin molded body is
The end of the sheath, the coated portion of the insulated wire protruding from the end of the sheath, the conductor portion of the insulated wire protruding from the coated portion, and the electronic component to which the conductor portion is connected are placed. A holder member including a mounting portion to be mounted and a frame portion surrounding the mounting portion.
Formed from the end of the sheath mounted on the mounting portion, the covering portion of the insulated wire, the conductor portion of the insulated wire, and a cover member that covers the electronic component together with a part of the holder member. Being done
At least the surface of the frame portion of the holder member is welded to the cover member by the heat generated when the cover member is formed.
To the surface of the frame portion, the projection pieces bite into the cover member is formed,
In addition to the surface of the frame portion, the rear end surface of the holder member is also covered with the cover member and welded to the cover member.
The protrusions are also formed on the rear end surface of the holder member.
A method for manufacturing a cable with a resin molded body.

In the method for manufacturing a cable with a resin molded body according to claim 1,
The protrusion piece is formed over the entire length of the frame portion.
A method for manufacturing a cable with a resin molded body.

In the method for manufacturing a cable with a resin molded body according to claim 1 or 2.
The protruding piece has a cross-sectional shape that gradually tapers as it separates from the surface of the frame portion.
A method for manufacturing a cable with a resin molded body.

In the method for manufacturing a cable with a resin molded body according to any one of claims 1 to 3 .
The protrusions formed on the surface of the frame and the protrusions formed on the rear end surface are a series.
A method for manufacturing a cable with a resin molded body.

In the method for manufacturing a cable with a resin molded body according to claim 4 .
A series of second protrusions along the protrusions are formed on the outside or inside of the protrusions.
A method for manufacturing a cable with a resin molded body.

In the method for manufacturing a cable with a resin molded body according to claim 5 .
It has a plurality of crosslinked protrusions formed between the protrusion and the second protrusion and extending in a direction intersecting the protrusion and the second protrusion.
One end of each of the crosslinked protrusions is connected to the protrusion, and the other end is connected to the second protrusion.
A method for manufacturing a cable with a resin molded body.

In the method for manufacturing a cable with a resin molded body according to any one of claims 1 to 6 .
The electronic component is a sensor.
A method for manufacturing a cable with a resin molded body.

In the method for manufacturing a cable with a resin molded body according to claim 7 .
The sensor is a magnetic sensor that outputs a signal according to a change in an ambient magnetic field.
A method for manufacturing a cable with a resin molded body.